Orthotic shell

ABSTRACT

An orthotic shoe insert having a contoured body adapted to support a location of a wearer&#39;s foot between a heel and a medial arch, the body being constructed of a semi-rigid material and including a rear concave end and a forward extending and medial arch supporting edge. The body exhibits a three dimensional shape and perimeter defining outer profile adapted for being inserted into the wearer&#39;s shoe. Corresponding methods for forming an orthotic shoe insert can include either providing a thermoplastic material in an unformed lay-flat sheet of varying thickness and rigidity, then applying a heat source to the material to assisting in forming the material into a three dimensional shape including a concave rear and heel supporting end and a forward extending and medial arch supporting end. Other methods include pre-placing scrim layers within opposing surfaces of mating die halves and post-injecting a plasticized material in fluidic state in order to form the insert.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims the benefit of U.S. Provisional Application 61/809,049 filed on Apr. 5, 2013, the contents of which are incorporated herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to orthotic insert technology. More specifically, the present invention discloses a formable shell for an orthotic shoe insert. The shell utilizes a proprietary thermoplastic substrate, such as which exhibits a semi-rigid material, with a scrim overlaying each of top and bottom surfaces.

In one preferred variant, the shell is pre-formed and incorporates a cupped heel portion having a concave upper surface and continuously extends with varying thickness and density to a location just past the patient's (wearer's) medial arch. The formable shell also allows for easy adhesion of upper and lower die-cut (scrim) layers, such further including of any of foam, leather, fabric or other formed shapes, and which are selected to accommodate the contours of a patient's foot.

As will be further described in additional detail, the shell can be reformed to specific contours using an external heat source and can be produced such as in a die or mold assembly in which, in a first method, a semi-rigid and thermoplastic material is initially provided in an unformed lay-flat sheet of varying thickness, following which a heat source is applied to the material to assist in forming the material into a three dimensional shape including a concave rear and heel supporting end and a forward extending and medial arch supporting end.

A related forming process contemplates a two piece die or mold, in which upper and lower scrim layers are placed into mating and cavity defining surfaces prior to or during a three dimensional forming process in which a plasticized material is injected between the scrim layers and upon closing the mold. Additional features can include pre-cutting of the scrim layers to match a profile of the three dimensional formed material, with other additional steps including the scrim layers provided in a tautened sheet form and subsequently edge trimmed to match a contour of the three dimensionally formed material.

BACKGROUND OF THE INVENTION

The prior art is well documented with examples of orthotic insert designs. A first example of this is depicted in the orthotic midsole for footwear in WO 2012/092135, also CA 2823151 and which discloses, in relevant part, an orthotic shell 18 including a heel portion 50 for supporting a heel of a wearer's foot and a forefoot portion 52 to support a forefoot of the wearer behind and near the metatarsal heads of the foot. A midfoot portion 53 extends between the heel portion 50 and the forefoot portion 52 and generally corresponds to the plantar surfaces of a typical wearer's foot, such as the arch. The orthotic shell is shaped such that that, when it is supported at the determined orientation, the heel portion 50 partially cups the wearer's heel to support the same in a generally vertical orientation. Simultaneously, the forefoot portion 52 supports the forefoot such that the metatarsal heads are supported in a neutral, generally horizontal manner.

Other examples drawn from the prior art include the orthotic insole of Supple, US 2014/0053430, the foot orthotic of Andrews US 2013/0312279, and the orthotic insert assembly of Veldman US 2013/0192088.

SUMMARY OF THE INVENTION

The present invention discloses an orthotic shoe insert including a contoured body adapted to support a location of a wearer's foot between a heel and a medial arch. The body is constructed of a semi-rigid material and includes a rear concave end and a forward extending and medial arch supporting edge. The body further exhibits a three dimensional shape and perimeter defining outer profile adapted for being inserted into the wearer's shoe.

In additional versions, the body can be constructed of a polypropylene and/or polyethylene blend material. At least one scrim layer can be applied to either an upper and/or lower surface of the body, the scrim layer further including any of a foam, fabric or leather material. Additional features include the body varying in at least one of thickness and density between the rear concave end and the forward extending edge.

A corresponding method for forming an orthotic shoe insert includes the steps of providing a semi-rigid and thermoplastic material in an unformed lay-flat sheet of varying thickness and rigidity, then applying a heat source to the material to assist in forming the material into a three dimensional shape including a concave rear and heel supporting end and a forward extending and medial arch supporting end. Additional steps include applying the heat source through the use of any of a hot air gun, hot water, convection oven, conventional oven, infrared or targeted microwave generated heat and of forming the insert by any of a die, stamping or closed mold in which one or both of cavity defining die surfaces can be heated to facilitate forming and setting of the material into the desired shape.

Yet additional steps include providing the material in either of a liquid or semi-molten form in a combined polypropylene/polyethylene/scrim blend extrusion. Other steps include applying at least one scrim layer to either an upper and/or lower surface of said formed material, such exhibiting any of a foam, fabric or leather material, and of varying at least one of a thickness or density of the material between the rear concave end and the forward extending end.

The step of pre-positioning the scrim layers can further include providing upper and lower scrim layers into cavity defining surfaces of the die prior to or during three dimensional forming, as well as pre-cutting the scrim layers to match a profile of the three dimensional formed material. Other steps include the scrim layers provided in a tautened sheet form and subsequently edge trimmed to match a contour of the three dimensionally formed material.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which:

FIG. 1 is a first illustration of a pair of orthotic shell inserts according to one non-limiting embodiment of the present invention;

FIG. 2 is a further side perspective of the orthotic shell inserts better depicting its edge contours;

FIG. 3 is an illustration showing upper and lower scrim layers placed into cavity defining surfaces of associated die halves prior to or during three dimensional forming, as well as depicting pre-cutting of the scrim layers to match a profile of the three dimensional formed material, with other additional steps including the scrim layers provided in a tautened sheet form and subsequently edge trimmed to match a contour of the three dimensionally formed material;

FIG. 4 is a partially exploded side cutaway of the die halves depicted in FIG. 3, with the scrim layers pre-applied to the opposing inner cavity defining surfaces;

FIG. 5 is a succeeding depiction of the die or mold halves of FIGS. 3 and 4 in a closed or sandwiched position in which a volume of fluidized polymeric material is in-filled under pressure between the scrim layers and into the cavity defining interior; and

FIG. 6 is an illustration of another process for forming a three dimensional orthotic insert and which can include providing a heated or softened blank or sheet which is subsequently shaped or formed, such as by a template pressing upon the sheet, into a three dimensional end configuration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to each of FIGS. 1-2, the present invention depicts a pair of orthotic shell inserts, see at 10 and 12 are shown in each of right side up (at 10) and upside down (at 12) fashion, according to one non-limiting variant of the present invention. The orthotic shells 10 and 12 typically represent left/right feet, each in one variant being made of a proprietary thermoplastic or other suitable and semi-rigid material such as which can incorporate any desired polypropylene/polyethylene blend. As will be described in further detail, the shells can also be provided in varying thicknesses with each further including a scrim or covering layer, see as further shown at 14 for insert 10 and at 16 for insert 12.

The scrim layers can, without limitation, further include any of foam, leather, fabric or other formed shapes and which are selected to accommodate the contours of a patient's (wearer's) foot. In one non-limiting application the shell 10 or 12 is pre-formed and incorporates a cupped heel portion (see as best shown for selected shell 10 with depicted upper scrim surface 14) having a concave upper surface and which continuously extends with varying thickness, as well as varying the material density of the semi-rigid material, to a location just past the patient or wearer's medial arch as depicted by forward edges 18 and 20 of the shells 10 and 12, respectively.

The cupped heel portion, depicted only at 22 for selected shell 10 given further shell 12 is shown inverted, is separated from the associated forward and medial arch supporting edge 18 by first 24 and second 26 contoured sides as best shown in the side perspective of FIG. 2. An outer perimeter defining edge associated with each orthotic insert is configured to exhibit a three dimensional extending profile (see again as best shown by inner cupped end, outer side edge 24 and forward medial arch terminating edge 18) uniquely dimensioned for accommodating the anatomical and physiological aspects of the wearer's heel and arch.

An associated forming process contemplates the shell being provided as a semi-rigid and thermoplastic material in an unformed lay-flat sheet of varying thickness, a depiction of which is shown at 25 in in FIG. 6 prior to processing or external forming. An external heat source, generally depicted at 27 and including such as any of a hot air gun, hot water, convection oven, conventional oven, infrared or targeted microwave generated heat, and the like, is employed in a fashion which assists in forming the shell, such as in particular the mid-foot or foremost sections of the heel cup.

As further shown in FIG. 6, the lay-flat sheet 25 can be provided as a blank of a plasticized material, and which is stamped/formed in a recess mold (see for example lower die cavity in FIG. 3) by a suitably molded template (see further at 29 in FIG. 6) and which presses the softened sheet into contact with the recessed cavity in order to provide the desired three dimensional configuration. As further depicted by cutout lines 31 and 33, the blank or sheet 25 can be pre-formed with the overall configuration of the completed insert or, alternatively, the perimeter edges of the template 29 can include a blade edge for sectioning the sheet with the desired perimeter contours, such as occurring concurrent with the three dimensional forming process. Likewise, upper and lower scrim layers (see as depicted by selected scrim layer 35) can also be pre-placed into contact with at least one of the upper and lower surfaces of the heated plasticized blank 25 and prior to forming into the desired three dimensional shape.

Beyond that described above, Any form of die, stamping or closed mold can alternately be employed (see below as further described in FIGS. 3-5) in forming the orthotic shell, and such as in which one or both of the inner cavity defining die surfaces can be heated to facilitate forming and setting of the orthotic insert in the desired shape. The orthotic shell can also be made from a thermoforming process incorporating a combined polypropylene and/or polyethylene/scrim blend extrusion.

Alternatively, a multiple extrusion forming process can be employed in which varying plasticized materials are concurrently formed to produce both the semi-rigid and thermoplastic base material and either one or a pair of outer scrim layers. In one non-limiting possibility, one or more layers can be separately provided or combined in blank or sheet form, this generally designated by layer 25 in FIG. 6 which can represent a semi-rigid and thermoplastic layer alone or in combination with either or both upper and lower scrim layers. Without limitation, the plasticized materials employed in any of the processes described herein can include any known or proprietary blend of materials suited for a particular application.

Alternatively, formation of the shell can also contemplate pre-positioning or placing upper and lower scrim layers, such as again at 14 and 16, into any mold or die and forming/adhering them in the desired fashion with the semi-rigid blend material. The scrim layers can also be pre-cut to match the profile of the orthotic shell or can be provided in a tautened sheet form and subsequently edge trimmed, such as according to the desired forming process employed.

Additional features include the shells cupped heel portion (such as again shown at 22) accommodating most foot contours and allow formability to a patient's foot when used in conjunction with any desired foam/fabric/leather or other suitable upper scrim or cover, again at 14. The orthotic shell can also be used with or without a bottom covering formed to the patient's foot or feet and/or can be used with a fabric/foam/leather cover in a reduced-length should a full-length cover not be appropriate for the patient.

Yet additional features include providing the orthotic insert shell in a unique size for a shoe insert, thus allows flexibility for making either a full or ¾ length shoe orthotic. It is also envisioned that the bottom of the heel cup area (see at 28 in FIG. 1 for selected insert 12) can exhibit an anti-slip feature which assists in positioning the orthotic and reducing movement within the wearer's shoe.

With reference now to FIGS. 3-5, a further mold or die assembly and process is disclosed for forming the three dimensional orthotic insert as described in FIGS. 1-2 and which includes, with initial reference to FIG. 3, providing of upper 30 and lower 32 scrim layers placed into cavity defining surfaces, further at 34 and 36, of an associated die (see further upper die half 38 and lower hinged or otherwise secured die half 40, these further including mating outer perimeter profiles 39 and 41 respectively), this occurring prior to or during three dimensional forming of the orthotic insert. Upon closing the die or mold halves, an injection molded plastic 42 (see in FIG. 5) is provided in a molten form, typically under pressure, for delivery to communicating surface locations of the cavity defining surfaces (see also interior communication channel depicted in phantom at 43 in FIG. 3).

FIG. 4 is a partially exploded side cutaway of the die halves depicted in FIG. 3, with the scrim layers 30 and 32 pre-applied to the opposing inner cavity defining surfaces, with FIG. 5 being a succeeding depiction of the die or mold halves of FIGS. 3 and 4 in a closed or sandwiched position in which the volume of fluidized polymeric material is in-filled under pressure between the scrim layers and into the cavity defining interior.

As previously described, the completed article can exhibit varying thicknesses along its length and between a thickest cupped heel end and the forward most medial arch terminating edge 18 (this best shown in FIG. 5). Other associated features include pre-cutting of the scrim layers 28 and 30 to match a profile of the three dimensional formed material, with other additional steps including the scrim layers provided in a tautened sheet form and subsequently edge trimmed to match a contour of the three dimensionally formed material.

It is also envisioned that the die process of FIGS. 3-5 can be reconfigured so that the pre-placed scrim layers 30 and 32 are substituted by a multiple or triple extrusion process in which multiple plasticized materials are co-extruded or tri-extruded through a variation of the die assembly in which multiple injection nozzles are employed to provide each of the semi-rigid thermoplastic material and the outer scrim layers. In this variant, the scrim layers are likely provided as a lighter foamed plastic which is multi-extruded with the more rigid main thermoplastic layer in order to produce the finished article.

Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims. 

I claim:
 1. An orthotic shoe insert, comprising: a contoured body adapted to support a location of a wearer's foot between a heel and a medial arch, said body being constructed of a semi-rigid material and including a rear concave portion bounded by a raised heel edge and a forward extending and medial arch supporting edge; and said body exhibiting a three dimensional shape and perimeter defining outer profile adapted for being inserted into the wearer's shoe.
 2. The insert as described in claim 1, said body having a specified shape and size and being constructed of a polypropylene/polyethylene blend material.
 3. The insert as described in claim 1, further comprising at least one scrim layer applied to either an upper and/or lower surface of said body.
 4. The insert as described in claim 3, said scrim layer further comprising any of a foam, fabric or leather material.
 5. The insert as described in claim 1, said body having a specified shape and size and varying in at least one of thickness and density between said rear concave end and said forward extending edge.
 6. A method for forming an orthotic shoe insert, comprising the steps of: providing a semi-rigid and thermoplastic material as a lay-flat sheet of varying thickness; applying a heat source to said material; and forming the material into a three dimensional shape including a rear concave portion bounded by a raised heel edge and a forward extending and medial arch supporting edge.
 7. The method as described in claim 6, further comprising the step of applying the heat source through the use of any of a hot air gun, hot water, convection oven, conventional oven, infrared or targeted microwave generated heat.
 8. The method as described in claim 6, said step of forming into a three dimensional shape further comprising providing any of a die, stamping or closed mold in which one or both of cavity defining die surfaces can be heated to facilitate forming and setting of the material into the desired shape.
 9. The method as described in claim 6, further comprising the step of providing said material in at least one of a liquid or semi-molten form in a combined polypropylene and/or polyethylene scrim blend extrusion.
 10. The method as described in claim 8, further comprising the step of applying at least one scrim layer to either an upper and/or lower surface of said formed material.
 11. The method as described in claim 10, said step of applying said scrim layer further comprising extruding upper and lower scrim layers against opposite sides of said semi rigid and thermoplastic material.
 12. The method as described in claim 6, further comprising the step of said material varying in at least one of thickness or rigidity between said rear concave end and said forward extending end.
 13. The method as described in claim 10, further comprising the step of pre-positioning upper and lower scrim layers into cavity defining surfaces of said die prior to or during three dimensional forming.
 14. The method as described in claim 13, further comprising the step of pre-cutting said scrim layers to match a profile of the three dimensional formed material.
 15. The method as described in claim 13, further comprising the step of trimming said scrim layers to match a contour of the three dimensionally formed material.
 16. A method for forming an orthotic shoe insert, comprising the steps of: providing upper and lower dies, each including a mating and recessed interior; placing at least one scrim layer into at least one of said die recessed cavities; and upon closing said dies, infilling a fluidic plasticized material in order to fill a cavity defined by opposing interior surfaces of said dies and between said scrim layers.
 17. The method as described in claim 16, further comprising the step of said scrim layer exhibiting any of a foam, fabric or leather material.
 18. The method as described in claim 16, further comprising the step of pre-positioning upper and lower scrim layers into upper and lower recess cavity defining surfaces of said dies prior to three dimensional forming.
 19. The method as described in claim 16, further comprising the step of pre-cutting said scrim layers to match a profile of the three dimensional formed material.
 20. The method as described in claim 16, further comprising the step of provided said scrim layers in a tautened sheet form and subsequently edge trimming to match a contour of the three dimensionally formed material. 